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diff --git a/fabrication-and-operation-instructions/wpr-assembly.tex b/fabrication-and-operation-instructions/wpr-assembly.tex new file mode 100644 index 0000000..6b1c070 --- /dev/null +++ b/fabrication-and-operation-instructions/wpr-assembly.tex @@ -0,0 +1,348 @@ +%% document +\documentclass[11pt]{article} +\usepackage[letterpaper, portrait, margin=0.75in]{geometry} +\usepackage{setspace} +\usepackage{color} + +% text +\usepackage[utf8]{inputenc} +\setlength\parindent{0pt} +\setlength{\parskip}{1em} +\renewcommand{\familydefault}{\sfdefault} +\newcommand{\RomanNumeral}[1]{\textrm{\uppercase\expandafter{\romannumeral #1\relax}}} + +% math +\usepackage{amssymb} +\usepackage{amsmath} +\usepackage[cm]{sfmath} +\usepackage{commath} +\usepackage{multirow} +\DeclareMathAlphabet{\mathpzc}{OT1}{pzc}{m}{it} + +% graphics +\usepackage{graphics} +\usepackage{graphicx} +\usepackage{epsfig} +\usepackage{epstopdf} +\usepackage{xpatch} +\usepackage{pdfpages} +\usepackage{float} + +% each section begins new page +\let\stdsection\section +\renewcommand\section{\clearpage\stdsection} + +% hyperref +\usepackage[colorlinks=true, linkcolor=black, urlcolor=blue, citecolor=black, anchorcolor=black]{hyperref} +\usepackage[all]{hypcap} % helps hyperref work properly + + + +\usepackage[shortlabels]{enumitem} +\setlist[enumerate, 1]{nosep} +\setlist[enumerate, 2]{nosep, topsep=-5ex} +\setlist[enumerate, 3]{nosep, topsep=-5ex} +\setlist[enumerate, 4]{nosep, topsep=-5ex} +\setlist[itemize, 1]{nosep} +\setlist[itemize, 2]{nosep, topsep=-5ex} +\setlist[itemize, 3]{nosep, topsep=-5ex} +\setlist[itemize, 4]{nosep, topsep=-5ex} + +% bibliography +\usepackage[numbers]{natbib} + +% title +\title{Wisconsin Photoreactor \\ Assembly Instructions} +\author{ + Philip Lampkin \\ + Blaise J. Thompson \\ + Samuel H. Gellman + } +\date{\today} + +\begin{document} + +\maketitle + +\includegraphics[width=\textwidth]{"../coverart.jpg"} + +\tableofcontents + +\section{Introduction} + +The Wisconsin Photo-Reactor (WPR) is made to be easily assembled. +This document is meant to help chemists accomplish this assembly. +Each reactor has two major components requiring detailed custom assembly: + +\begin{itemize} + \item The 3D printed enclosure, described in \autoref{SEC:enclosure} + \item The drive electronics, described in \autoref{SEC:electronics} +\end{itemize} + +With these two major components complete, assembly of the WPR is relatively straight-forward. +Details of final assembly are described in \autoref{SEC:assembly}. + +Throughout this document we refer to an online repository containing source and design files. +This repository appears at \url{https://github.com/uw-madison-chem-shops/wisconsin-photoreactor}. +This repository contains everything including the source for this very document. + +A working WPR is made up of many separate commercially available parts. +This guide assumes that you have already done the work of procuring those parts. +The online repository contains several README files with detailed part numbers and suggested vendors. + +The WPR is a living project. +We welcome and encourage duplication and modification of our designs and documentation. +If you notice problems or omissions within this assembly document, please consider opening an issue or pull request. + +\section{3D Printed Enclosure} \label{SEC:enclosure} + +\includegraphics[width=\textwidth]{"./3dp-coverat.jpg"} + +The body of the WPR is made up of three main pieces: + +\begin{itemize} + \item Base, containing LEDs, fan, and drive electronics. + \item Top plate accepting reaction vials. + \item Chamber walls spacing the top plate at the appropriate distance away from the base. +\end{itemize} + +The WPR base is the same for all reactors. +Look within the repository in the subdirectory ``photoreactor-base'' to find design and production files to produce the WPR base. +You will also need to print a cable anchor, see files in that same directory. + +The top plate and chamber height must be specified for the particular reaction vessels used. +Four examples for different vial sizes are pictured above. +Look within the repository in the subdirectory ``photoreactor-tops'' to find existing designs. +We encourage you to design your own if none of these suit your application. +Consider adding your new designs to repository so that others may benefit from your design efforts. + +When interacting with the design files in our online repository you will see several different filetypes. +We have designed the WPR enclosure using Fusion 360, and have included those f3d design files for those that wish to extend or modify the designs. +Interacting with f3d files will require a Fusion 360 license. +You will also find stl files in the online repository. +These are common 3D-model exchange files which can be viewed using any 3D modeling program. +In fact, GitHub itself has a built in stl viewer which you may use to inspect our designs. + +There are many options for getting your enclosures printed. +We recommend white PLA as a material, although any white material should work---we have also used ABS. +If you are printing yourself, follow the instructions provided by your printer to produce slices and program your printer. +Note that you will need support material for the base. +Any company or shop offering 3D printing as a service should be able to accept our stl files without further modification. + +We have succesfully printed using the following printers: + +\begin{itemize} + \item Ender 3 + \item Stratasys uPrint SE Plus + \item Ultimaker 3 +\end{itemize} + +Once your parts are done you may need to remove extra bonding material with a razor blade or exacto-knife. +The three pieces of your reactor should fit together snugly and securely. + +\clearpage + +\begin{center} + \includegraphics[width=0.5\textwidth]{"./heat-insert.jpg"} +\end{center} + +Each WPR base contains seven threaded heat inserts. +These allow components such as the drive circuit board to rigidly attach to the base via machine screws. +Use a soldering iron to carefully heat these while pushing them into their cavities. + +\section{Electronics} \label{SEC:electronics} + +\includegraphics[width=\textwidth]{"./electronics-coverart.jpg"} + +The WPR incorporates small circuit boards controlling the incorporated LED and fan. +We refer to these small boards as ``drivers''. +There are two types available: the ``analog-driver'' and ``digital-driver''. +Refer to the associated directories in the online repository for design files for each of these. + +Both drivers are built around Mean Well's LDD-1000L LED driver module. +This module delivers constant current up to one amp. +The current delivered can be controlled electronically in several different ways. +WPR users wishing to understand this design should refer to Mean Well's datasheet. + +The analog-driver circuit is made to be as simple as possible. +The circuit accepts DC 12 V through a barrel jack. +A small knob is used to adjust light intensity. +Fan speed is not adjustable. +Refer to \autoref{SEC:analog-driver} for analog-driver assembly instructions and further explanation. + +The digital-driver circuit is made to be incorporated into an I$^2$C-based digital control system. +In addition to power, these boards have 4-pin connectors to carry the I$^2$C serial data. +The digital-driver is pictured above, without any connectors attached. +Refer to \autoref{SEC:digital-driver} for digital-driver assembly instructions and further explanation. + +When interacting with the design files in our online repository you will see several different filetypes. +These circuit boards were designed using KiCad, a free and open source electronics CAD software. +All KiCad files are contained within the ``kicad'' subdirectories. +You may modify and extend these designs however you like. + +Those wishing to reproduce our designs should refer to the gerber subdirectory. +Within the gerber directory you will find zip files for each separate version of the PCB. +You may upload these zip files to PCB manufacturers when ordering copies of our designs. + +\clearpage +\subsection{Analog} \label{SEC:analog-driver} + +The analog driver circuit is meant to be as simple as possible while still allowing for reproducible LED intensity control. +To this end, the number of components has been minimized as much as possible. +A full schematic of the analog circuit appears at the end of this section. +A bill of materials appears within the README of the online repository. + +\begin{center} + \includegraphics[width=\textwidth/2]{"./bare-pcb.jpg"} +\end{center} + +Your PCB manufacturer will send you a bare board, as seen above. + +\begin{center} + \includegraphics[width=\textwidth/2]{"./surface-mount.jpg"} +\end{center} + +Begin by adding the surface mount components. +Recommend thin solder, e.g. 0.015''. +The LED does have a polarity---ensure that the small green line points towards ground (left). +Once done your board should look like the above. + +\begin{center} + \includegraphics[width=\textwidth/2]{"./connectors.jpg"} +\end{center} + +Next, add the connectors and the potentiometer knob. +From now on we recommend standard gage solder, e.g. 0.031''. +Once done your board should look like the above. + +\begin{center} + \includegraphics[width=\textwidth/2]{"./barrels-tested.jpg"} +\end{center} + +Next, add the barrel jacks and the test points. +With these added you may plug in your board for the first time. +You should see your power indicator LED illuminate. +You should also be able to adjust the DC control voltage relative to ground by turning the knob, as shown above. + +\begin{center} + \includegraphics[width=\textwidth/2]{"./pcb-driver.jpg"} +\end{center} + +Finally, add the Mean Well LED driver. +Note that this component goes on the back of the PCB, as shown above. + +\includepdf[landscape=true]{"../analog-driver/driver.pdf"} + +\subsection{Digital} \label{SEC:digital-driver} + +The digital driver circuit can be controlled from a computer or some other digital device. +We built our driver to work over I2C, consistent with an emerging standard for many ``maker'' products. +While the physical connectors may be different, our digital circuit is compatible with the following systems. + +\begin{itemize} + \item \href{https://learn.adafruit.com/introducing-adafruit-stemma-qt}{Adafruit STEMMA} + \item \href{https://www.sparkfun.com/qwiic}{Sparkfun Qwiic} + \item \href{https://www.seeedstudio.com/category/Grove-c-1003.html}{Seeed Grove} +\end{itemize} + +\begin{center} + \includegraphics[width=\textwidth/2]{"./digital-wired.jpg"} +\end{center} + +Each digital driver is based around an ATtiny85 microcontroller acting as an I2C peripheral. +Multiple digital driver boards may be ``networked'' together onto one I2C bus by simply daisy-chaining the boards together, as shown above. +In such a use-case you must choose a unique I2C address for each ATtiny85 peripheral. + +\begin{center} + \includegraphics[width=\textwidth/2]{"./redboard.jpg"} +\end{center} + +There are many ways to interface with the I2C bus. +We have used a SparkFun RedBoard, pictured above. +You may find an example within the online repository that dynamically controls both the LED intensity and fan speed. + +\includepdf[landscape=true]{"../digital-driver/driver.pdf"} + +\section{Assembly} \label{SEC:assembly} + +\includegraphics[width=\textwidth]{"./assembly-coverart.jpg"} + +Once 3D printing is done and PCBs have been filled, WPR assembly is fairly straight-forward. +The various electronic components must be installed into the base (pictured above), as described in \autoref{SEC:base}. +Reflective coating must be added to the chamber walls, as described in \autoref{SEC:top}. +After these final steps, your WPR is ready for synthesis! + +\clearpage +\subsection{Base} \label{SEC:base} + +\begin{center} + \includegraphics[width=\textwidth/2]{"./bare-led.jpg"} +\end{center} + +If possible, it's best to order your LEDs pre-attached to an ``LED star'' heat sink. +Otherwise you may order bare LED stars and discrete LEDs. +Either way, you will have a filled LED star as pictured above. +In this example we are using LED Supply part number 07007-PL000-F. + +\begin{center} + \includegraphics[width=\textwidth/2]{"./soldered-led.jpg"} +\end{center} + +Start by soldering leads onto your LED star, using the red positive black negative convention. +Soldering here may be challenging, as the LED star itself will resist your efforts to heat it. +Adding some lead-based solder may help, due to the lower melting point. + +\begin{center} + \includegraphics[width=\textwidth/2]{"./tap-heatsink.jpg"} +\end{center} + +The aluminum heatsinks arrive preformed but without any tapping. +Tap the heatsink for imperial 4-40 machine screws. +We used thread-forming tap: OSG 1400105300 with a pneumatic ``air-tapper'' (pictured above), but you may do this by hand if you wish. +You will need to tap just two of the innermost holes. + +\begin{center} + \includegraphics[width=\textwidth/2]{"./led-and-heatsink.jpg"} +\end{center} + +Install the LED star and heatsink with wires facing towards printed hole. +Use 1/4'' screws. + +\begin{center} + \includegraphics[width=\textwidth/2]{"./mounted-fan.jpg"} +\end{center} + +Install the fan. +Pay special attention to the orientation of the fan, including the location of the cord. +Use 3/4'' screws here. + +\begin{center} + \includegraphics[width=\textwidth/2]{"./cable-tie.jpg"} +\end{center} + +Install the cable anchor using a 1/4'' screw. +Use a zip tie to capture the fan cord, as shown above. + +\clearpage + +\begin{center} + \includegraphics[width=\textwidth/2]{"./driver-on-base.jpg"} +\end{center} + +Install the driver board using the threaded standoffs. +Plug the LED and fan into the board. +Pay special attention to the orientation of the fan connector. +You should now be ready to test your base---remember to use proper eye protection! + +\clearpage +\subsection{Top} \label{SEC:top} + +\begin{center} + \includegraphics[width=\textwidth/2]{"./reflector.jpg"} +\end{center} + +Simply cut the reflective material to line the chamber. +It's good to leave overlap around the interior, as shown. +Remove the backing and stick the material to the chamber walls. + +\end{document} |